METHOD STATEMENT

REpAIRS OF CONCRETE SpALLING OR HONEYCOmBING

PRODUCTS Xypex Concentrate Xypex Megamix II

(TO BE READ IN CONJUNCTION WITH pRODUCT DATA SHEETS)

GENERAL: This method statement details the products and procedures to carry out concrete repairs where the concrete is spalling or is honeycombed. Note: If water flows are present within the defect, it will be necessary to stop the flows. Refer to the Method Statement for Sealing of Cracks and Faulty Construction Joints. SURFACE PREPARATION: Saw cut the perimeter of the repair area to a minimum depth of 10mm. Remove all loose and delaminating material until a sound substrate is exposed. Removal of deteriorated concrete is generally achieved by mechanical scabbling or hydro-demolition. If mechanical scabbling is undertaken, the exposed area must be made free of all dirt and loose material. Xypex requires a Saturated Substrate and Damp surface (SSD). Concrete surfaces must be thoroughly saturated with clean water prior to the application. Remove excess surface water before the application. If concrete surface dries out before application, it must be re-wetted. All corroded steel must be exposed, generally the substrate is removed to a minimum of 20mm beyond the corroded reinforcement (this requirement may be varied by engineering directives). Once exposed the reinforcement must be cleaned of rust and scale. Where necessary, replace the corroded reinforcement bar (specification governing the reinforcement replacement requirements are the responsibility of the project engineer). APPLICATION: 1. Saturate the concrete with clean water so as to achieve a SSD surface. 2. Mix Xypex Concentrate, five (5) parts powder to two (2) parts clean water into a slurry and apply a brush coat of the material on to the prepared reinforcement steel. 3. Mix Xypex Megamix II with clean water. Add approximately 90% of the water to a mixer and then add the Xypex Megamix II powder. Mix briefly and add additional water as required to a maximum of 2.8 litres per 20 kg bucket. 4. Apply a scrub coat of this mixed material to the prepared, saturated concrete surface. While the scrub coat is still green, apply Xypex Megamix II to the repair areas. 5. Xypex Megamix II should be applied in layers not greater than 50mm in thickness. Allow each layer to reach initial set before applying subsequent layers, the surface should be scratched to allow for increased bond of subsequent layers.

Issued: January 2013

METHOD STATEMENT

XYpEx AUSTRALIA NEW SOUTH WALES 190 Toongabbie Road GIRRAWEEN NSW 2145 (02) 9896 4999 VICTORIA 39 Cambro Road CLAYTON VIC 3168 (03) 9543 7933 QUEENSLAND 8/93 Burnside Road STAPYLTON QLD 4207 (07) 3442 4300 SOUTH AUSTRALIA Unit 1, 30 Raglan Avenue EDWARDSTOWN SA 5039 (08) 8297 1288 WESTERN AUSTRALIA 1/44 Sustainable Drive BIBRA LAKE WA 6163 (08) 9434 3844 HEAD OFFICE 45 Union Road NORTH ALBURY NSW 2640 (02) 6040 2444 www.xypex.com.au

Curing: 6. The repaired areas should be protected from rapid drying out by using continuous moist curing methods for a minimum three days or by using a curing compound which is compliant to AS 3799 or ASTM C309. Notes: In situations where an improved finished appearance is required it is recommended that the final application be Xypex Megamix I. If enhanced waterproofing or durability is required it is recommended that a coat of Xypex Concentrate is applied over the completed Xypex Megamix II surface.

DISCLAIMER Although every care is taken by Xypex Australia to ensure that the material contained in this publication is accurate, Xypex Australia does not guarantee the suitability of the use of its products in every situation. The reader of this material must make their own judgment as to the suitability of the product for the intended use. Xypex Australia accepts no responsibility for unsuitable use, incomplete works, poorly applied product or any errors in this publication.

Application Schematic - Repairs of Concrete Spalling or Honeycombing

Application of Xypex Concentrate and Xypex Megamix II

10mm saw cut

Xypex Megamix II

Xypex Concentrate slurry

Xypex Australia. 2012 45 Union Road North Albury NSW 2640 Ph +61 2 6040 2444 xypenq@xypex.com.au www.xypex.com.au
This schematic is intended as a graphic example only. Refer to Product Data Sheet or Method Statement for application instructions.

10mm saw cut

Issued: January 2013